NHTSA Complaint #10532184 — 2006 FORD F-150

THE RIGHT EXHAUST MANIFOLD STUDS HAD BROKEN APPROXIMATELY 5/5/2012, IN WHICH THEY DID NOT TELL ME THE FULL EXTENT OF THE DAMAGES. THEY JUST TOLD ME THE MANIFOLD WAS LEAKING AND THE COST TO REPAIR IT. THIS CAUSED THE MANIFOLD TO WARP AND LEAK. THE DEALER WOULD NOT REPAIR IT UNDER THE EXTENDED WARRANTY. APPROXIMATELY ONE YEAR LATER I CALLED THE WARRANTY COMPANY AND FOUND OUT IT WAS ACTUALLY COVERED. WHEN I HAD TAKEN IT IN, IN MAY 2012 THE DEALER WANTED TO CHARGE 1500.00 FOR THE REPAIRS. THE REPAIRS WERE FINALLY MADE IN MAY OF 2013 TO THE EXHAUST MANIFOLD, BUT NOT TO THE CATALYTIC.CONVERTER WHICH STARTED CAUSING PROBLEMS IN JANUARY OF THIS YEAR. THIS LEAK MAY HAVE CAUSED THE RIGHT CATALYTIC CONVERTER TO FAIL ALSO, BUT HAVE FOUND MANY FORUMS STATING THAT FAILURE OF THE CATALYTIC CONVERTERS ARE A COMMON PROBLEM ON THESE PICK UPS. AT THIS TIME I AM DRIVING THE PICK UP AND IT THROWS THE CODE P0420, FOR CATALYTIC CONVERTER BELOW EFFICIENCY THRESHOLD. THIS PROBLEM SHOULD ALSO BE FORWARDED TO THE E.P.A. BECAUSE PEOPLE CANNOT AFFORD TO REPLACE THEIR CATALYTIC CONVERTERS AT THE PRICE OF 1200.00 PER SIDE. IF THIS IS A COMMON PROBLEM WITH FORD F-150'S THIS NEEDS ADDRESSED. ALSO THE FAILURE OF THE EXHAUST MANIFOLD IS A SAFETY HAZARD THAT COULD CAUSE THE OCCUPANTS IN THE CABIN TO BE EXPOSED TO CARBON MONOXIDE. THE LEAKING MANIFOLD ALSO CONFUSES THE COMPUTER BY TELLING IT THAT THE OF BANK CYLINDERS IS RUNNING TO LEAN IN RESPONSE TO THOSE READINGS IT THEN ADDS FUEL TO THAT BANK WHICH CAUSES IT TO RUN RICHER ON THAT BANK THAN IT SHOULD. I BELIEVE THAT THIS CAUSED DAMAGE TO THE CATALYTIC CONVERTER MAKING IT FAIL PREMATURELY. *TR